Systems and methods for manufacture of orthodontic appliances

ABSTRACT

In some embodiments, apparatuses and methods are provided herein useful to providing data files associated with orthodontic appliances. In some embodiments, a system for providing data files associated with orthodontic appliances comprises a database, wherein the database stores the data files associated with the orthodontic appliances and a control circuit, wherein the control circuit is communicatively coupled to the database, a user device, and a printer, wherein the control circuit is configured to receive, from the user device, an indication of a selected orthodontic device, retrieve, based on the indication of the selected orthodontic device from the database, one of the data files associated with the orthodontic appliances, wherein the one of the data files associated with the orthodontic appliances corresponds to the selected orthodontic appliance, and transmit, to the printer, the one of the data files associated with the orthodontic appliances.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Application No. 16/875,618,filed May 15, 2020, which claims benefit of U.S. Provisional ApplicationNo. 62/931,679, filed Nov. 6, 2019, which are both incorporated byreference in their entirety herein.

TECHNICAL FIELD

This invention relates generally to orthodontics and, more specifically,the manufacture of orthodontic appliances

BACKGROUND

Orthodontic clinicians seek to correct malocclusions by use of manydifferent devices, such as braces, retainers, pallet expanders,positioners, etc. Braces, one of the most commonly used appliances,include brackets, archwires, and ligatures. The brackets are affixed toa patient’s teeth and the archwire passes through slots in the bracketsdesigned to receive the archwire. The ligatures secure the archwirewithin the slots. Because no two patients have identical malocclusionsor facial geometries, the prescription for each patient’s braces must beselected by the clinician. A prescription for braces typically includesspecifically selected brackets, archwires, and ligatures. Accordingly,many clinicians attempt to keep a variety of orthodontic applianceson-hand so as to be able to promptly treat patients. Unfortunately,doing so can be cost prohibitive. For example, a large practice may havean orthodontic bracket inventory costing over $50,000. Not only doesthis bracket inventory represent a large overhead for clinicians, it canprevent smaller practices from being able to do business. Consequently,a need exists for systems, methods, and apparatuses that minimize theneed for clinicians to stock a large number of orthodontic appliances totreat patients.

BRIEF DESCRIPTION OF THE DRAWINGS

Disclosed herein are embodiments of systems, apparatuses, and methodspertaining to providing data files associated with orthodonticappliances. This description includes drawings, wherein:

FIG. 1 is a diagram depicting operations between a user device 102, abackend server 104, and a printer 106 to additively manufacture anorthodontic appliance, according to some embodiments;

FIG. 2 is a block diagram of a system 200 for providing data filesassociated with orthodontic appliances, according to some embodiments;

FIG. 3 is a flow chart including example operations for providing datafiles associated with orthodontic appliances, according to someembodiments;

FIG. 4 depicts a user interface 402 for selecting orthodonticappliances, according to some embodiments;

FIG. 5 depicts selection of a prescription type for an orthodonticappliance via a user interface 502 for selecting orthodontic appliances,according to some embodiments;

FIG. 6 depicts selection of a type of orthodontic appliance via a userinterface 602 for selecting orthodontic appliances, according to someembodiments;

FIG. 7 depicts selection of a type of orthodontic appliance via a userinterface 702 for selecting orthodontic appliances, according to someembodiments;

FIG. 8 depicts a modification menu 804 of a user interface 802 forselecting orthodontic appliances, according to some embodiments;

FIG. 9 depicts modification of an orthodontic appliance via selectionsof a modification menu 904 of a user interface 902 for selectingorthodontic appliances;

FIG. 10 depicts a print menu 1004 of a user interface 1002 for selectingorthodontic appliances, according to some embodiments;

FIG. 11 depicts a pricing menu 1104 or a user interface 1102 forselecting orthodontic appliances, according to some embodiments;

FIGS. 12A and 12B depict isometric and plan views, respectively, of base1200 of a kit including orthodontic appliances, according to someembodiments;

FIGS. 13A and 13B depicts a kit 1300 including orthodontic applianceshaving a base 1302 and a lid 1304, according to some embodiments;

FIGS. 14A and 14B depict a bracket 1402 including a bonding surface 1408that has a compound curvature, according to some embodiments;

FIG. 15 depicts a bracket 1502 including a dovetail 1504 through abonding surface 1506 of the bracket 1502, according to some embodiments;

FIG. 16 is a side elevational view of a bracket 1602 depicting anundercut area 1604 of tiewings 1606, according to some embodiments;

FIG. 17 is an isometric view of a bracket 1702 including dovetails 1704and undercut areas 1706 of tiewings 1708, according to some embodiments;

FIG. 18 depicts a convertible bracket 1802, according to someembodiments;

FIG. 19 is an isometric view of a bracket 1902 connected to a base 1904via support structures 1906, according to some embodiments;

FIG. 20A is an isometric view of a bracket 2002, according to someembodiments; and

FIG. 20B is an isometric view of a base 2004, according to someembodiments.

Elements in the figures are illustrated for simplicity and clarity andhave not necessarily been drawn to scale. For example, the dimensionsand/or relative positioning of some of the elements in the figures maybe exaggerated relative to other elements to help to improveunderstanding of various embodiments of the present invention. Also,common but well-understood elements that are useful or necessary in acommercially feasible embodiment are often not depicted in order tofacilitate a less obstructed view of these various embodiments of thepresent invention. Certain actions and/or steps may be described ordepicted in a particular order of occurrence while those skilled in theart will understand that such specificity with respect to sequence isnot actually required. The terms and expressions used herein have theordinary technical meaning as is accorded to such terms and expressionsby persons skilled in the technical field as set forth above exceptwhere different specific meanings have otherwise been set forth herein.

DETAILED DESCRIPTION

Generally speaking, pursuant to various embodiments, systems,apparatuses, and methods are provided herein useful to providing datafiles associated with orthodontic appliances. In some embodiments, asystem for providing data files associated with orthodontic appliancescomprises a database, wherein the database stores the data filesassociated with the orthodontic appliances and a control circuit,wherein the control circuit is communicatively coupled to the database,a user device, and a printer, wherein the control circuit is configuredto receive, from the user device, an indication of a selectedorthodontic device, retrieve, based on the indication of the selectedorthodontic device from the database, one of the data files associatedwith the orthodontic appliances, wherein the one of the data filesassociated with the orthodontic appliances corresponds to the selectedorthodontic appliance, and transmit, to the printer, the one of the datafiles associated with the orthodontic appliances.

As previously discussed, because no two patients have identical dentalor facial structures, many orthodontic appliances are specially designedor selected for each patient. While some orthodontic appliances arecustom-molded for patients, such as clear aligners, other orthodonticappliances, such as brackets, come in a variety of prescriptions and areselected by the clinician based on the patient’s dental and/or facialgeometry. With regard to brackets, clinicians select from among thecommercially available prescriptions to choose brackets for each of apatient’s teeth. While the total number of commercially availablebrackets is quite large, a smaller subset of all brackets is used totreat the majority of patients. For example, though the total number ofcommercially available brackets numbers in the thousands, the majorityof patients are treated using only about 20% of those brackets.Accordingly, orthodontic practices may try to keep all of these “common”brackets on hand so that patients can be analyzed and treated promptly(e.g., during the same day, week, etc.). While maintaining such a largeinventory may be feasible for large practices, maintaining, or building,such an inventory may be cost prohibitive for small and/or newpractices. Additionally, even if a practice is capable of maintainingsuch an inventory, it is likely not cost effective.

Described herein are systems, methods, and apparatuses that seek toovercome this problem by allowing clinicians to quickly and affordablymanufacture orthodontic appliances, such as brackets. In one embodiment,clinicians are provided with data files (e.g., computer-aided designfiles (CAD), such as .stl files). The clinicians then manufactureorthodontic appliances based on the data files with additivemanufacturing. As one example, a clinician can select a bracket that heor she would like to use to treat a patient. The system provides a datafile associated with the bracket to the clinician. The clinician then,using a 3D printer, manufactures the bracket in his or her office. Thismanufacturing-on-demand eliminates, or at least reduces, the number ofbrackets that a clinician must have on hand to promptly treat patients.Not only does this allow clinicians to promptly treat patients, but italso reduces costs for the clinician and thus the patient. Thediscussion of FIG. 1 provides an overview of such a system.

FIG. 1 is a diagram depicting example operations between a user device102, a backend server 104, and a printer 106 to additively manufacturean orthodontic appliance, according to some embodiments. The exampleoperations depicted in FIG. 1 include operations amongst the componentsof FIG. 1 . FIG. 1 depicts operations at stages A - H. The stages areexamples and are not necessarily discrete occurrences over time (e.g.,the operations of different stages may overlap). Additionally, FIG. 1 isan overview of example operations.

At stage A, the user device 102 presents a user interface to the user.The user device 102 is, for example, a computing device (e.g., a desktopor laptop computer, tablet, smartphone, etc.). The user interfaceincludes a catalogue. The catalogue includes orthodontic appliances thatare available. For example, the catalogue can include all orthodonticappliances that can be additively manufactured. In one embodiment, thecatalogue is much like a traditional catalogue including orthodonticappliances for purchase. That is, the user can browse the availableorthodontic appliances and select orthodontic appliances. The cataloguecan include orthodontic appliances that are directly bonded (i.e.direct-bond orthodontic appliances) and/or removable orthodonticappliances (i.e., orthodontic appliances that are not affixed to thepatient in a semi-permanent nature). For example, directly bondedorthodontic appliances can include brackets, buccal tubes, buttons,class II correctors, etc. and removable orthodontic appliances caninclude aligners, removable class II correctors, expanders, retainers,positioners, etc.

At stage B, the user device 102 receives user selections. The userselections can include selections of orthodontic devices. Additionally,in some embodiments, the user can make selections to modify theorthodontic appliances. In such embodiments, the catalogue can include anumber of base orthodontic appliances (e.g., an orthodontic appliance ofeach type with default parameters). For example, the base orthodonticappliance can be a mini molar tube having default parameters orspecifications (e.g., the mini molar tube can have an M-D width of.115”, O-G height of .115 inches, Tip of zero degrees, Torque of 14degrees, Offset of 7 degrees, Archwire Slot Width of 0.022”, and In/Outof 0.033”). The user can then modify the mini molar tube by altering aslot width, a tip angulation, a tongue angulation, an offset angulation,a mesial-distal width, an occlusal-gingival height, an in-out height, amesial-distal base radius, an occlusal-gingival base radius, a type ofhook, a presence of a hook, a location of a hook, etc. of the mini molartube. The modifications can be selections based on a discrete scale(e.g., the archwire slot can vary from 0.01” to 0.025” in 0.001”increments, the bracket can either include or not include a mesial hook,etc.) and/or be virtually infinitely adjustable. The user can select asingle bracket, a group of brackets (e.g., a set of brackets for onepatient’s mouth), a pack of brackets (e.g., commonly used brackets tostore in inventory), etc.).

At stage C, the user device 102 transmits an indication of the userselections to a backend server 104. For example, if the user selects 28brackets (i.e., a group of brackets for a single patient’s mouth), theuser device 102 transmits an indication of each of the brackets selectsby the user.

At stage D, the backend server 104 receives the indication of the userselections. The backend server 104 can be of any suitable type, and isgenerally responsible for processing the user selections, retrievingdata files based on the user selections, and transmitting the datafiles. In some embodiments, the system can operate in a thin clientmanner. In such embodiments, the user device 102 can access thecatalogue via the backend server 104. Additionally, or alternatively,some of the processing can be performed on the user device 102. Forexample, in some embodiments, the user device 102 may store a copy ofthe catalogue and present the catalogue to the user, as well as allowthe user to make selections from the catalogue, via an applicationexecuting on the user device 102.

At stage E, the backend server 104 retrieves the data files. The datafiles are associated with orthodontic appliances. For example, the datafiles can be CAD files, such as .cad, .fbx. stl,.form, etc. files, andinclude engineering drawings for the orthodontic appliances. Theengineering drawings of the orthodontic appliances are suitable for usein manufacturing the orthodontic appliances. That is, the data filesinclude information sufficient to additively manufacture an orthodonticappliance. The backend server 104 retrieves the data files that areassociated with the user’s selections. For example, if the user selectsa Lower Anterior bracket with an M-D width of .115”, O-G height of .151inches, Tip of zero degrees, Torque of -6 degrees, Offset of 0 degrees,Archwire Slot Width of 0.022”, In/Out of 0.045”, No Mesial Hook, NoGingival Hook, O-G Base Radius of 0.625, and M-D Base Radius of 0.375”,the backend server 104 retrieves the data file associated with a LowerAnterior bracket anterior bracket having these parameters. In someembodiments, the data files are generated, and stored in a database,before the time at which they are requested. That is, the data files arepre-generated and need not be created at the time of retrieval. In suchembodiments, data files may be created for each permutation of eachbracket and stored in a database for quick and easy retrieval.Alternatively, in some embodiments, at least some of the data files arenot pre-generated. For example, in some embodiments, only data files forthe base brackets may be pre-generated. In such embodiments, the datafiles for the base brackets are modified to when a user makesmodifications to the base bracket.

At stage F, the backend server 104 transmits the data files. The backendserver 104 can transmit the data files to the user device 102 and/or theprinter 106, dependent upon the environment. For example, in oneembodiment, the backend server 104 transmits the data files to the userdevice 102 (stage G₂) and the user device 102 transmits the data filesto the printer 106 for printing. Alternatively, the backend server 104transmits the data files directly to the printer 106 (stage G₁) forprinting. In either case, the data files may be secured so thatorthodontic appliances based on the data files may only be manufacturedonce. That is, the user may purchase a number of prints of each datafile, as opposed to purchasing the data file. For example, if the userselects only a single bracket and one copy of the single bracket, insuch embodiments the user is only able to print the single bracket once.Such control can be achieved by any suitable means, such as single-useencryption, transmission of data files directly to the printer 106,using specific file formats (e.g., file formats that are difficult tomanipulate, proprietary, etc.), etc. In some embodiments, the user canpurchase a subscription (e.g., an unlimited number of prints for amonth, a specified number of prints for a week, etc.).

At stage H, the printer 106 prints the orthodontic appliances associatedwith the data files. Though this description refers to a printer 106printing an orthodontic appliance, embodiments are not so limited andthe term “printing” is used herein to generally refer to any suitableadditive manufacturing process.

While the discussion of FIG. 1 provides an overview of operationsperformed by a system to additively manufacture orthodontic appliances,the discussion of FIG. 2 provides additional detail regarding such asystem.

FIG. 2 is a block diagram of a system 200 for providing data filesassociated with orthodontic appliances, according to some embodiments.The system 200 includes a control circuit 202, a database 204, a userdevice 210, and a manufacturing device 218. One or more of the controlcircuit 202, the database 204, the user device 210, and themanufacturing device 218 are communicatively coupled via a network 208.The network 208 can include a local area network (LAN) and/or wide areanetwork (WAN), such as the internet. Accordingly, the network 208 caninclude wired and/or wireless links.

The user device 210 can be any suitable type of computing device (e.g.,a desktop or laptop computer, smartphone, tablet, etc.). The user device210 includes a display device 212. The display device 212 is configuredto present a catalogue to a user. The catalogue includes orthodonticappliances that the user can obtain via the system 200. For example, thecatalogue can include all orthodontic devices that the user can purchaseand/or manufacture via the manufacturing device 218. The user interactswith the catalogue via a user input device 214. The user can interactwith the catalogue by navigating the catalogue, making selections fromthe catalogue, modifying orthodontic appliances included in thecatalogue, etc. Accordingly, the user input device 214 can be of anysuitable type, such as a mouse, keyboard, trackpad, touchscreen, etc.The user device 210 also includes a communications radio 216. Thecommunications radio 216 transmits and receives information for the userdevice 210. For example, in the case of a smartphone, the communicationsradio 216 can be a cellular radio operating in accordance with the 4GLTE standard. Once a user has made a selection of an orthodonticappliance, the user device 210, via the communications radio 216 and thenetwork 208, transmits an indication of the selection to the controlcircuit 202.

The control circuit 202 can comprise a fixed-purpose hard-wired hardwareplatform (including but not limited to an application-specificintegrated circuit (ASIC) (which is an integrated circuit that iscustomized by design for a particular use, rather than intended forgeneral-purpose use), a field-programmable gate array (FPGA), and thelike) or can comprise a partially or wholly-programmable hardwareplatform (including but not limited to microcontrollers,microprocessors, and the like). These architectural options for suchstructures are well known and understood in the art and require nofurther description here. The control circuit 202 is configured (forexample, by using corresponding programming as will be well understoodby those skilled in the art) to carry out one or more of the steps,actions, and/or functions described herein.

By one optional approach the control circuit 202 operably couples to amemory. The memory may be integral to the control circuit 202 or can bephysically discrete (in whole or in part) from the control circuit 202as desired. This memory can also be local with respect to the controlcircuit 202 (where, for example, both share a common circuit board,chassis, power supply, and/or housing) or can be partially or whollyremote with respect to the control circuit 202 (where, for example, thememory is physically located in another facility, metropolitan area, oreven country as compared to the control circuit 202).

This memory can serve, for example, to non-transitorily store thecomputer instructions that, when executed by the control circuit 202,cause the control circuit 202 to behave as described herein. As usedherein, this reference to “non-transitorily” will be understood to referto a non-ephemeral state for the stored contents (and hence excludeswhen the stored contents merely constitute signals or waves) rather thanvolatility of the storage media itself and hence includes bothnon-volatile memory (such as read-only memory (ROM) as well as volatilememory (such as an erasable programmable read-only memory (EPROM).

The control circuit may be remote from the user device 210 and/or themanufacturing device 218. For example, the user device 210 and themanufacturing device 218 may be located in a clinician’s office (e.g.,the user’s office) whereas the control circuit 202, and possibly thedatabase 204, are cloud-based. The control circuit 202 generallyoperates to retrieve data files 206 based on the user’s selection oforthodontic appliances. The control circuit 202 retrieves the data files206 from the database 204. The database 204 is configured to store thedata files 206. The data files 206 are associated with orthodonticappliances. The data files 206 are CAD files from which the orthodonticdevices can be manufactured. The database 204 stores a data file foreach of the orthodontic appliances included in the catalogue. In oneembodiment, the database 204 stores a data file for all possiblepermutations of each orthodontic appliance (e.g., every possiblemodification and/or combination or modifications for each orthodonticappliance). The control circuit 202 receives the indication of theorthodontic appliance and retrieves a data file based on the indicationof the orthodontic appliance.

It should be noted that the indication of the orthodontic appliance mayinclude more than one orthodontic appliance. For example, the indicationof the orthodontic appliance can include multiple orthodonticappliances, such as full set of brackets for a patient. Accordingly, thedata file can be a file including instructions and/or specifications formultiple orthodontic appliances. For example, the data file may includemultiple data files and/or multiple specifications for a number ofbrackets.

After retrieving the data file, the control circuit 202 transmits thedata file. In some embodiments, the control circuit 202 encrypts orotherwise protects the data file before transmission. The controlcircuit 202 can encrypt or otherwise protect the data file beforetransmission to prevent those other than the user from accessing thedata file. Additionally, in some embodiments, the control circuit 202can encrypt or otherwise protect the data file to control the user’saccess to the data file. For example, in some embodiments, the system isset up such that user’s pay on a per manufacture or per print basis.That is, the user does not purchase, and may not later have access to,the data file. Rather, the user purchases access to print or otherwisemanufacture an orthodontic appliance based on the data file once (orother specified number of times).

Dependent upon the embodiment, the control circuit 202 transmits thedata file to the user device 210, the manufacturing device 218, or athird-party device (e.g., a laboratory capable of manufacturing theorthodontic appliance for the user). To whom, or to what device, thedata file is transmitted may also aid in achieving access control. Forexample, in one embodiment, the control circuit 202 transmits the datafile directly to the manufacturing device 218. Because the data file isnot transmitted to the user device 210, the data file may not be easilyaccessible by the user device 210. Further, if an entity that controlsthe control circuit 202 controls the manufacturing device 218, accessmay to files received by the manufacturing device 218 may be furtherlimited. In some embodiments, the control circuit 202 transmits the datafiles to the user device 210. In such embodiments, the user device 210transmits, via the communications radio (e.g., over a universal serialbus (USB) connection, wireless connection based on the 802.11 standard,etc.), the data files to the manufacturing device 218.

The manufacturing device 218 additively manufacturers the orthodonticappliance(s) based on the data file. The manufacturing device 218 can beof any suitable type, such as a 3D printer. The manufacturing device 218can be local to, or remote from, one or more of the control circuit 202and the user device 210. For example, in one embodiment, the user device210 and the manufacturing device 218 are located in the user’s office(i.e., the user device 210 and the manufacturing device 218 are local toone another). Alternatively, the manufacturing device 218 may be locatedin a laboratory or some other facility that manufactures orthodonticappliances for the user.

While the discussion of FIG. 2 provides additional detail regarding asystem for providing data files associated with orthodontic appliances,the discussion of FIG. 3 describes example operations of such a system.

FIG. 3 is a flow chart including example operations for providing datafiles associated with orthodontic appliances, according to someembodiments. The flow begins at block 302.

At block 302, data files are generated. For example, a human user and/orcomputer program can generate the data files. The data files areassociated with orthodontic appliances. The data files are associatedwith orthodontic appliances such that the data files can be used tomanufacture or otherwise produce orthodontic appliances based on thedata files. In one embodiment, the data files are CAD files. The datafiles can be generated before, or at the time of, retrieval. The flowcontinues at block 304.

At block 304, the data files are stored. For example, a database canstore the data files. The database can be of any suitable type and storethe data files in any suitable manner. For example, the database can bea relational database, a NoSQL database, etc. The database stores thedata files after they are generated. The flow continues at block 306.

At block 306, a catalogue is presented. For example, a user device canpresent the catalogue to a user. The catalogue includes orthodonticappliances that the user can purchase or otherwise obtain. The user canbrowse the catalogue and make selections via the user device. The flowcontinues at block 308.

At block 308, selection of an orthodontic appliance is received. Forexample, the user device can receive a selection of an orthodonticappliance. The selection of the orthodontic appliance can indicate whichorthodontic appliance the user would like to manufacture and, in someembodiments, can also indicate modifications to the orthodonticappliance. For example, the catalogue can include a number of baseorthodontic appliances. At least some of the base orthodontic appliancesare modifiable by the user. The user selection can include an indicationof the modifications. The flow continues at block 310.

At block 310, an indication of the orthodontic appliance is transmitted.For example, the user device can transmit an indication of theorthodontic appliance via a network. The indication of the orthodonticappliance indicates which orthodontic appliance(s) the user has chosenas well as any modifications to the orthodontic appliance(s). The flowcontinues at block 312.

At block 312, the indication of the orthodontic appliance is received.For example, a control circuit can receive the indication of theorthodontic appliance. The flow continues at block 314.

At block 314, a data file is retrieved. For example, the control circuitcan retrieve the data file from the database. The data file isassociated with the orthodontic appliance. That is, the data fileincludes the instructions and/or parameters necessary to manufacture theorthodontic appliance that the user has selected. In some embodiments,the control circuit can encrypt or otherwise protect the data file. Asone example, the control circuit can encode the data file with singleuse encryption. The flow continues at block 316.

At block 316, the data file is transmitted. For example, the controlcircuit can transmit the data file. The control circuit can transmit thedata file to the user device and/or a manufacturing device. The flowcontinues at block 318.

At block 318, the data file is received. For example, the data file canbe received by the user device and/or the manufacturing device. If thedata file is received by the user device, the user device transmits thedata file to the manufacturing device. The flow continues at block 320.

At block 320, the orthodontic appliance is manufactured. For example,the manufacturing device can manufacture the orthodontic appliance. Themanufacturing device can be of any type suitable to additivelymanufacture the orthodontic appliance. For example, the manufacturingdevice can be a 3D printer.

While the discussion of FIGS. 1 - 3 provides detail regarding a systemfor providing data files associated with orthodontic appliances, thediscussion of FIGS. 4 - 11 describe a user’s interaction with such asystem via a user interface.

FIG. 4 depicts a user interface 402 for selecting orthodonticappliances, according to some embodiments. In FIG. 4 (as well as FIGS.5 - 11 ), the user interface 402 is being presented via a web browser400. It should be noted that this is just one example. In someembodiments, a software application specific to the catalogue mayexecute on the user device. In such embodiments, the user interface maybe presented via the software application. Whether the system operatesas a thin client or a thick client, the general functionality remainsthis same. Consequently, the description provided in FIGS. 4 - 11 ,though directed to an example in which the system operates as a thinclient, is applicable to thick client embodiments as well.

FIG. 4 depicts a root menu 408 of the user interface 402. The root menu408 includes a number of selections. In FIG. 4 , the user is on thefirst step, as indicated by user selection of a select prescription menu404. Selection of the select prescription selection 404 causes the userinterface 402 to present different prescription types 406 from which theuser can select. In some embodiments, the prescription types 406 includestandard prescriptions known in the art as well as the option to createa new prescription (“Add New!”).

FIG. 5 depicts selection of a prescription type for an orthodonticappliance via a user interface 502 for selecting orthodontic appliances,according to some embodiments. As shown in FIG. 5 , the user hasselected the MBT 508 prescription type from a select prescription menu506. Selection of the MBT 508 prescription type causes the userinterface 502 to present orthodontic appliances for each of a patient’steeth, including a first set of brackets 510 for the top row of thepatient’s teeth and a second set of brackets 512 for the bottom row ofthe patient’s teeth. In some embodiments, the brackets of the first setof brackets 510 and the second set of brackets 512 are automaticallypopulated by upon selection of a prescription type. For example, theuser interface can be prepopulated with common brackets, suggestedbrackets (e.g., based on a scan of the patient’s mouth provided to thesystem), brackets previously selected by the user, etc.

FIG. 6 depicts selection of a type of orthodontic appliance via a userinterface 602 for selecting orthodontic appliances, according to someembodiments. As depicted in FIG. 6 , the user has selected theorthodontic appliance type 606. Selection of the orthodontic appliancetype 606 presents a menu 608 of different types of orthodonticappliances from which the user can select. At this stage, the userinterface 602 presents a graphic 610 of each tooth and the orthodonticappliance, if any, selected for that tooth.

FIG. 7 depicts selection of a type of orthodontic appliance via a userinterface 702 for selecting orthodontic appliances, according to someembodiments. In FIG. 7 , the user has selected the convertible tubeselection 710 from the menu 706 of different types of orthodonticappliances. The user has also selected teeth from the graphic 708 withwhich he or she would like to associate convertible tubes. As depictedin FIG. 7 , the user has selected the upper first molars 704. Thegraphic 708 allows the user to visualize his or her selections as he orshe develops the prescription for the patient.

FIG. 8 depicts a modification menu 804 of a user interface 802 forselecting orthodontic appliances, according to some embodiments. Asdepicted in FIG. 8 , the user has selected a modification menu 804. Themodification menu 804 allows the user to make changes to the parametersof the orthodontic appliances. For example, as depicted in FIG. 8 , theuser can modify the slot width 806 of the orthodontic appliance, the tip808 of the orthodontic appliance, the torque 810 of the orthodonticappliance, the offset 812 of the orthodontic appliance, themesial-distal (M-D) width 814 of the orthodontic appliance, the in/out816 of the orthodontic appliance, the presence of a mesial hook 818 onthe orthodontic appliance, and the presence of a distal hook 820 on theorthodontic appliance. A greater number of, or fewer, modifications arepossible as desired, and the modifications provided herein are simplyexamples of modifications that a user may wish to make.

As depicted in FIG. 8 , each of the modifications includes anincremented bar 822. The user can adjust the modifications based on thisincremented bar 822. The incremented bar 822 is incremented as suitedfor the modification. For example, the presence of a mesial hook isbinary (i.e., either the orthodontic appliance will have or will nothave a mesial hook) and thus the incremented bar 822 associated with themesial hook modification has two increments.

FIG. 9 depicts modification of an orthodontic appliance via selectionsof a modification menu 904 of a user interface 902 for selectingorthodontic appliances. As depicted in FIG. 9 , the user has selectedthe lower right first bicuspid. Upon selection of a tooth, the userinterface 902 presents an expanded view 906 of the orthodontic appliancefor the selected tooth. Here, the user has selected a bracket 908 forthe selected tooth. In the expanded view 906, the user can select from anumber of views, as indicated by markers 910. The number of views caninclude front elevation, rear elevation, isometric, top, bottom,sectional, etc. views. Additionally, in some embodiments, one or more ofthe views can be dynamic. For example, in one or more of the views, theuser may be able to manipulate a virtual representation of the bracket908. As depicted in FIG. 9 , the user has manipulated the incrementedbars 914 to modify the bracket 908 as desired.

FIG. 10 depicts a print menu 1004 of a user interface 1002 for selectingorthodontic appliances, according to some embodiments. In FIG. 10 , theuser has selected the print menu 1004. Selection of the print menu 1004causes the user interface 1002 to present printers from which the usercan select. In the example depicted in FIG. 10 , the user can selectfrom three printers: Printer 1 1006, Printer 2 1008, and Printer 3 1010.As depicted in FIG. 10 , the user has selected Printer 3 1010. Selectionof Printer 3 1010 causes the user interface 1002 to present a printerdialogue 1012 associated with Printer 3. The printer dialogue 1012includes information about Printer 3 1010, such as the type of resininstalled 1014, estimated print time 1016, number of layers 1018, volumeof material to be used 1020, color additive to be used 1022, etc.

FIG. 11 depicts a pricing menu 1104 or a user interface 1102 forselecting orthodontic appliances, according to some embodiments.Selection of the pricing menu 1104 causes the user interface 1102 topresent a pricing details dialogue 1106. The pricing details dialogue1106 presents pricing information for the user. For example, the pricingdialogue 1106 can include a description of the orthodontic appliancesthat the user would like to order, a cost associated with each of theorthodontic appliances that the user would like to order, total costs,etc.

While the discussion of FIGS. 4 - 11 provides additional detailregarding a user interface for selecting orthodontic appliances, thediscussion of FIGS. 12 and 13 provide additional detail regardingmanufacture of sets of orthodontic appliances.

FIGS. 12A and 12B depict isometric and plan views, respectively, of base1200 of a kit including orthodontic appliances, according to someembodiments. The base 1200 includes a number of subtrays 1204. Each ofthe subtrays 1204 includes an orthodontic appliance 1208. In oneembodiments, the base 1200 and the orthodontic appliances 1208 areprinted as a single unit. In such embodiments, each of the orthodonticappliances 1208 is affixed to the base 1200 via support structures 1210.The support structures 1210 elevate the orthodontic appliances 1208 offof the base 1200. In some embodiments, the joint between the supportstructures 1210 and the orthodontic appliances 1208 is frangible tofacilitate easy separation of the orthodontic appliances 1208 from thebase 1200. For example, the joint can be designed to fracture at acertain point and in a predictable and/or desired manner (e.g., across aline or other geometry). The base 1200 also includes hinges 1206. Thehinges 1206 are designed to interface with a lid, as depicted in FIGS.13A and 13B.

FIGS. 13A and 13B depicts a kit 1300 including orthodontic applianceshaving a base 1302 and a lid 1304, according to some embodiments. Thelid 1304 is connected to the base via a hinge 1310. Though the kit 1300depicted in FIGS. 13A and 13B is of a clamshell design, embodiments arenot so limited. In some embodiments, the lid 1304 includes a latch 1306capable of interfacing with a detent 1308.

While the discussion of FIGS. 12 and 13 provide additional detailregarding manufacture of sets of orthodontic appliances, the discussionof FIGS. 14 - 18 depict example orthodontic appliances having geometriesthat would be difficult, if not impossible, to produce using traditionalmanufacturing techniques.

FIGS. 14A and 14B depict a bracket 1402 including a bonding surface 1408that has a compound curvature, according to some embodiments. Thebonding surface 1408 is the surface of the bracket 1402 that faces thepatient’s tooth. The surface of a patient’s tooth is a compound contourin that it has multiple different radii, each radius oriented in adifferent plane. As depicted in FIGS. 14A and 14B, the bonding surfaceincludes a compound curvature. The bonding surface 1408 includes amesial-distal radius 1410 and an occlusal-gingival radius 1412. Themesial-distal radius 1410 and the occlusal-gingival radius 1412 areoriented in planes that are perpendicular to one another (e.g., the X-Zplane and the Y-Z plane). In some embodiments, a scan of the patient’smouth is used to model the bonding surface 1408 of the bracket 1402.That is, in some embodiments, the bonding surface 1408 of the bracket1402 can be matched to fit the patient’s tooth.

The bracket 1402 in FIGS. 14A and 14B is mounted on a support structure1404. The support structure 1404 supports the bracket 1402 on a base1416. The support structure 1404 and the bracket 1402 meet at a joint1406. The support structure 1404 is configured to fracture at the joint1406 so that the bracket 1402 can be removed from the base 1416. Thebracket 1402 and the support structure 1404 can be separated byphysically breaking the joint, severing the joint with an instrumentsuch as a knife or scissors, etc. The base 1416 also include anidentifier 1414. The identifier 1414 indicates with which tooth thebracket 1402 is to be paired.

FIG. 15 depicts a bracket 1502 including a dovetail 1504 through abonding surface 1506 of the bracket 1502, according to some embodiments.The dovetail 1504 allows excess bonding material (e.g., adhesive) toflow from behind the bracket 1502. The dovetail 1504 follows thecurvature of the bonding surface 1506. As with the bracket depicted inFIGS. 14A and 14B, the bonding surface 1506 of the bracket 1502 includesa compound curvature. Creation of such a dovetail in the curved bondingsurface 1506 is extremely difficult, if not impossible, with traditionalmanufacturing techniques. However, such geometries are possible withadditive manufacturing.

With traditional manufacturing techniques, the bracket 1502 at thebonding surface 1506 would need to be thicker to accommodate a dovetailthat does not follow the compound curvature of the bonding surface 1506.Such thickness would place the bracket 1502 further from the facial axisof the tooth and result in compounding of tolerances. The end resultwould be less accurate placement and likely require additional adhesive.

FIG. 16 is a side elevational view of a bracket 1602 depicting anundercut area 1604 of tiewings 1606, according to some embodiments. Suchan undercut area 1604 allows a ligature to be more easily secured on thebracket 1602. The ligature would typically be stretched about all fourtiewings 1606, and the undercut area 1604 prevents the ligature frombecoming unsecured from the tiewings 1606 as it is secured to the othertiewings 1606. Such undercuts are extremely difficult, if notimpossible, to create with traditional manufacturing techniques.

FIG. 17 is an isometric view of a bracket 1702 including dovetails 1704and undercut areas 1706 of tiewings 1708, according to some embodiments.Both the tiewings 1708 with undercut areas 1706 and the dovetail 1704undercuts would be extremely difficult, if not impossible, to createwith traditional manufacturing techniques.

FIG. 18 depicts a convertible bracket 1802, according to someembodiments. The convertible bracket 1802 depicted in FIG. 18 isdesigned to be capable with, and without, an archwire. For example, at afirst time during treatment, a clinician may not want to use an archwirewith the convertible bracket 1802. However, as treatment progresses, useof the archwire may become beneficial. The clinician can anticipate thischange and place the convertible bracket 1802 before use of the archwireis needed.

The convertible bracket 1802 includes an archwire slot 1804. Thearchwire slot 1804 is covered by a top structure 1806. The top structure1806 closes off the archwire slot 1804 so that the bracket 1802 can beused without an archwire. If the clinician decides that he or she wouldlike to use the bracket 1802 with an archwire, the top structure 1806can be removed from the bracket 1802. The top structure 1802 meets themain bracket body 1810 at joints 1808. The joints 1808 are designed toallow the top structure 1806 to be removed from the main bracket body1810 so that the archwire slot 1804 is exposed.

Traditionally, brackets that were capable of converting this way weremade from multiple pieces of material. For example, a top structurewould be manufactured independently of a main bracket body. The topstructure would be welded or otherwise secured to the main bracket body.This type of manufacturing is expensive and difficult.

While the discussion of FIGS. 14 - 18 describes bracket geometriesand/or styles that are unique to the systems, methods, and apparatusdescribed herein, the discussion of FIGS. 19 - 20 describes manufactureof orthodontic appliances and bases.

FIG. 19 is an isometric view of a bracket 1902 connected to a base 1904via support structures 1906, according to some embodiments. In someembodiments, the bracket 1902, the support structures 1906, and the base1904 are manufactured (e.g., printed) as a single unit). The supportstructures 1906 join the bracket 1902 to the base 1904 at a joint 1908.In one embodiment, the joint 1908 has a double taper configuration. Inthe double taper configuration, both ends of the joint 1908 taper to asection that is, for example, thinner than the rest of the supportstructure 1906 or otherwise includes less material than the rest of thesupport structure 1906. The thinning of the support structure 1906 atthe joint 1908 allows the bracket 1902 to be detached from the base 1904by a user via physical input. The geometry of the joint 1908 focusesstress from physical manipulation of the bracket 1902 and/or base 1904at a desired location within the joint 1908. Accordingly, such joint1908 geometry allows for a clean fracture of the material at, or near,the joint 1908.

Additionally, in some embodiments, the locations, numbers, positions,etc. of the support structures 1906 can be user-defined. For example,the user can select precise locations of the support structures 1906based on the geometry of the bracket 1902. In such embodiments, thesupport structures 1906 can be included in the data file for the bracket1902. This provides the user with ability to locate the supportstructures 1906 as desired to facilitate clean and/or easier separationof the bracket 1902 from the base 1904.

FIG. 20A is an isometric view of a bracket 2002, according to someembodiments. FIG. 20B is an isometric view of a base 2004, according tosome embodiments. As depicted between FIGS. 20A and 20B, the bracket2002 is severable from the support structures 2006, and thus the base2004. In the example provided in FIGS. 20A and 20B, the placement of thesupport structures 2006 and the joints is such that nubs 2008 remain onthe bracket 2002 when the bracket 2002 is removed from the base 2004.

In some embodiments, a system for providing data files associated withorthodontic appliances comprises a database, wherein the database storesthe data files associated with the orthodontic appliances and a controlcircuit, wherein the control circuit is communicatively coupled to thedatabase, a user device, and a printer, wherein the control circuit isconfigured to receive, from the user device, an indication of a selectedorthodontic device, retrieve, based on the indication of the selectedorthodontic device from the database, one of the data files associatedwith the orthodontic appliances, wherein the one of the data filesassociated with the orthodontic appliances corresponds to the selectedorthodontic appliance, and transmit, to the printer, the one of the datafiles associated with the orthodontic appliances.

In some embodiments, the system further comprises the user device,wherein the user device includes a display device, wherein the displaydevice is configured to present, to a user, a catalogue, wherein thecatalogue include the orthodontic appliances, a user input device,wherein the user input device is configured to receive, from the user, aselection of the selected orthodontic appliance, and a communicationsradio, wherein the communications radio is configured to transmit, tothe control circuit, the indication of the selected orthodonticappliance.

In some embodiments, the user input device is further configured toreceive, from the user, user input to modify base versions of theorthodontic appliances, and wherein the selected orthodontic applianceis a modified version of a base version of the selected orthodonticappliance.

In some embodiments, the user input to modify the base versions of theorthodontic appliances includes one or more of modifying a slot width, atip angulation, a tongue angulation, an offset angulation, amesial-distal width, an occlusal-gingival height, an in-out height, amesial-distal base radius, an occlusal-gingival base radius, a type ofhook, a presence of a hook, and a location of a hook.

In some embodiments, the system further comprises the manufacturingdevice, wherein the manufacturing device is configured to receive, fromthe control circuit, the one of the data files associated with theorthodontic appliances, and manufacture, based on the one of the datafiles associated with the orthodontic appliances, the selectedorthodontic appliance.

In some embodiments, the manufacturing device is a printer, and themanufacturing device is further configured to verify, before printingthe selected orthodontic appliance, that a resin installed in theprinter is compatible with the selected orthodontic appliance.

In some embodiments, the one of the data files associated with theorthodontic appliances includes an indication of compatible resins, andwherein the manufacturing device verifies that the resin installed inthe manufacturing device is compatible with the selected orthodonticappliance based on the one of the data files associated with theorthodontic appliances.

In some embodiments, a system for additively manufacturing orthodonticappliances comprises a database storing data files associated with theorthodontic appliances, a user device, wherein the user device includesa display device, wherein the display device is configured to present,to a user, a catalogue, wherein the catalogue includes the orthodonticappliances, a user input device, wherein the user input device isconfigured to receive, from the user, a selection of one of theorthodontic appliances, and a communications radio, wherein thecommunications radio is configured to transmit, via a network, anindication of the one of the orthodontic appliances, a control circuit,wherein the control circuit is configured to receive, via the networkfrom the user device, the indication of the one of the orthodonticappliances, retrieve, from the database, one of the data filesassociated with the orthodontic appliances, wherein the one of the datafiles associated with the orthodontic appliances corresponds to theindication of the one of the orthodontic appliances, and transmit, viathe network to a manufacturing device, the one of the data filesassociated with the orthodontic appliances, and the manufacturingdevice, wherein the manufacturing device is configured to receive, viathe network from the control circuit, the one of the data filesassociated with the orthodontic appliances, and additively manufacture,based on the one of the data files associated with the orthodonticappliances, the one of the orthodontic appliances.

In some embodiments, an apparatus and a corresponding method performedby the apparatus comprises generating data files, wherein the data filesare associated with the orthodontic appliances, storing, in a database,the data files, presenting, by a display device of a user device, acatalogue, wherein the catalogue includes the orthodontic appliances,receiving, by a user input device of the user device, a selection of oneof the orthodontic appliances, transmitting, by a communications radioof the user device, an indication of the one of the orthodonticappliances, receiving, by a control circuit via a network, theindication of the one of the orthodontic appliances, retrieving, by thecontrol circuit from the database, one of the data files, wherein theone of the data files corresponds to the indication of the one of theorthodontic appliances, transmitting, by the control circuit via thenetwork, the one of the data files, receiving, by a manufacturing devicevia the network, the one of the data files, and additivelymanufacturing, by the manufacturing device based on the one of the datafiles, the one of the orthodontic appliances.

In some embodiments, a system for additively manufacturing orthodonticappliances comprises a database storing data files associated with theorthodontic appliances, a user device, wherein the user device includesa display device, wherein the display device is configured to present,to a user, a catalogue, wherein the catalogue includes the orthodonticappliances, a user input device, wherein the user input device isconfigured to receive, from the user, a selection of one of theorthodontic appliances, and a communications radio, wherein thecommunications radio is configured to transmit, via a network, anindication of the one of the orthodontic appliances, a control circuit,wherein the control circuit is configured to receive, via the networkfrom the user device, the indication of the one of the orthodonticappliances, retrieve, from the database, one of the data filesassociated with the orthodontic appliances, wherein the one of the datafiles associated with the orthodontic appliances corresponds to theindication of the one of the orthodontic appliances, and transmit, viathe network to the user device, the one of the data files associatedwith the orthodontic appliances, and the manufacturing device, whereinthe manufacturing device is configured to receive, via the network fromthe user device, the one of the data files associated with theorthodontic appliances, and additively manufacture, based on the one ofthe data files associated with the orthodontic appliances, the one ofthe orthodontic appliances.

Those skilled in the art will recognize that a wide variety of othermodifications, alterations, and combinations can also be made withrespect to the above described embodiments without departing from thescope of the invention, and that such modifications, alterations, andcombinations are to be viewed as being within the ambit of the inventiveconcept.

1-24. (canceled)
 25. A system for additively manufacturing orthodonticappliances, the system comprising: a database storing data filesassociated with the orthodontic appliances; and a control circuit,wherein the control circuit is configured to: receive, via a networkfrom a user device, an indication of a selected orthodontic appliance;retrieve, from the database, one of the data files associated with theorthodontic appliances, wherein the one of the data files associatedwith the orthodontic appliances corresponds to the indication of theselected orthodontic appliance; encode the one of the data filesassociated with the orthodontic appliances with access controls, whereinthe access controls define a number of prints of the one of the datafiles associated with the orthodontic appliances; and transmit, via thenetwork, the one of the data files associated with the orthodonticappliances.
 26. The system of claim 25, wherein the number of prints isbased on a number of prints purchased.
 27. The system of claim 25,wherein the number of prints is based on a subscription.
 28. The systemof claim 25, wherein the control circuit transmits the one of the datafiles associated with the orthodontic appliances to a manufacturingdevice.
 29. The system of claim 28, further comprising: themanufacturing device, wherein the manufacturing device is configured to:receive, from the control circuit via the network, the one of the datafiles associated with the orthodontic appliances; decode the one of thedata files associated with the orthodontic appliances; and manufacture,based on the one of the data files associated with the orthodonticappliances, the selected orthodontic appliance.
 30. The system of claim29, wherein the manufacturing device is an additive manufacturingdevice.
 31. The system of claim 25, wherein the control circuit encodesthe one of the data files associated with the orthodontic appliances byone or more of encrypting the one of the data files associated with theorthodontic appliances with single use encryption and encoding the oneof the data files associated with the orthodontic appliances in aproprietary format.
 32. A system for additively manufacturingorthodontic appliances, the system comprising: a database storing datafiles associated with the orthodontic appliances; and a control circuit,wherein the control circuit is configured to: receive, via a networkfrom a user device, an indication of a selected orthodontic appliance;retrieve, from the database, one of the data files associated with theorthodontic appliances, wherein the one of the data files associatedwith the orthodontic appliances corresponds to the indication of theselected orthodontic appliance; encrypt the one of the data filesassociated with the orthodontic appliances with single use encryption;and transmit, via the network, the one of the data files associated withthe orthodontic appliances.
 33. The system of claim 32, wherein thesingle use encryption allows the selected orthodontic appliance to onlybe printed a predefined number of times based on the one of the datafiles associated the orthodontic appliances.
 34. The system of claim 33,wherein the predefined number of times is based on a number of printspurchased.
 35. The system of claim 33, wherein the predefined number ofprints is based on a subscription.
 36. The system of claim 32, whereinthe control circuit transmits the one of the data files associated withthe orthodontic appliances to a manufacturing device.
 37. The system ofclaim 36, further comprising: the manufacturing device, wherein themanufacturing device is configured to: receive, from the control circuitvia the network, the one of the data files associated with theorthodontic appliances; decrypt the one of the data files associatedwith the orthodontic appliances; and manufacture, based on the one ofthe data files associated with the orthodontic appliances, the selectedorthodontic appliance.
 38. The system of claim 37, wherein themanufacturing device is an additive manufacturing device.
 39. A systemfor additively manufacturing orthodontic appliances, the systemcomprising: a database storing data files associated with theorthodontic appliances; a user device, wherein the user device isconfigured to: present, to a user, a catalogue, wherein the catalogueincludes the orthodontic appliances; receive, via a user input devicefrom a user, a selection of a selected orthodontic appliance; andtransmit, via communications radio to a control circuit, an indicationof the selected orthodontic appliance; the control circuit, wherein thecontrol circuit is configured to: receive, via a network from the userdevice, the indication of a selected orthodontic appliance; retrieve,from the database, one of the data files associated with the orthodonticappliances, wherein the one of the data files associated with theorthodontic appliances corresponds to the indication of the selectedorthodontic appliance; encode the one of the data files associated withthe orthodontic appliances with access controls, wherein the accesscontrols define a number of prints of the one of the data filesassociated with the orthodontic appliances; and transmit, via thenetwork, the one of the data files associated with the orthodonticappliances; a manufacturing device, wherein the manufacturing device isconfigured to: receive, via the network, the one of the data filesassociated with the orthodontic appliances; and additively manufacture,based on the one of the data files associated with the orthodonticappliances, the selected orthodontic appliance.
 40. The system of claim39, wherein the number of prints is based on a number of printspurchased.
 41. The system of claim 39, wherein the number of prints isbased on a subscription.
 42. The system of claim 39, wherein themanufacturing device receives the one of the data files associated withthe orthodontic appliances from the control circuit.
 43. The system ofclaim 39, wherein the manufacturing device receives the one of the datafiles associated with the orthodontic appliances from the user device.44. The system of claim 39, wherein the control circuit encodes the oneof the data files associated with the orthodontic appliances by one ormore of encrypting the one of the data files associated with theorthodontic appliances with single use encryption and encoding the oneof the data files associated with the orthodontic appliances in aproprietary format.